mafell SKS 130 Door Lock Mortiser Instruction Manual

SKS130
Door lock mortiser

Original operating instructions

MAF00853/a

WARNING!
These operating instructions contain important information on safe working practices for this machine.
It is therefore essential that you read these operating instructions carefully.

915524, 915525, 915526

Mafell AG
D – 78727 Oberndorf, den 28.07.2016

Signs and symbols

| This symbol appears at places where you will find instructions for your own safety.
Non-compliance with these instructions may result in very serious injuries.
---|---
| This symbol indicates a potentially hazardous situation.
If this situation is not avoided, the product or objects in its vicinity may get damaged.
| This symbol indicates tips for the user and other useful information.

Product information

for machines with a product no. 915501, 915502, 915503, 915520, 915521, 915522, 915523, 915524, 915525 or 915526

2.1 Manufacturer´s data
MAFELL AG, Postfach 1180, D-78720 Oberndorf / Neckar, Phone +49 (0)7423/812-0, Fax +49 (0)7423/812218

2.2 Machine identification
All details required for machine identification are available on the attached rating plate.

requirements according to Appendix I of the Machinery Directive.
| For EU countries only
Do not dispose of electric tools together with household waste material!
In accordance with the European directive 2002/96/EC on waste electrical and electronic equipment and transposition into national law, obsolete electrical tools must be collected separately and recycled in an environmentally compatible manner.
| To reduce the risk of injury, please read the operating instructions.

2.3 Technical data

Universal motor, radio, and TV interference suppressed| 230 V~, 50 Hz| 110 V~, 50 Hz
---|---|---
Input power continuous operation| 1600 W| 1600 W
Current at nominal load| 7.4 A| 15.4 A
Idling speed| 5770 rpm|
Mortising depth| 145 mm (5 3/4 in.)|
Weight without mains cable| 10,6 kg|

2.4 Noise emission specifications
Noise emission values determined according to EN 60745-1:

| Sound power level| Workplace-related emission value
---|---|---
Idling| 108 dB (A)| 97 dB (A)
Machining| 108 dB (A)| 97 dB (A)

The noise measurement was recorded using the mortising chain included in the standard equipment.
The values stated do not take into consideration any possible series variances and are not suitable for determining the immission sound pressure level, as the latter fluctuates in dependence on the time in service,  the respective type of machining, and the environmental influences. The immission sound pressure level can therefore only be determined on an individual basis at the machine user’s position.

2.5 Vibration specifications
The typical hand-arm vibration is 4.0 m/s

2. 2.6 Scope of supply
Door lock mortiser SKS 130 complete with:

2 guide rails completely
2 mortising chains
2 chain wheels
1 service tool in the bracket on the machine
1 carrying case
1 operating manual
1 folder “Safety Instructions”

2.7 Safety devices

Danger
These devices are required for the machine’s safe operation and may not be removed or rendered inoperative.

The machine is equipped with the following safety devices:

• Chainguard and protective cover
• Base plate with protective cam
• Large limit stop
• Handles
• Gas spring to prevent abrupt retraction
• Index mechanism with lock
• Hose connector

2.8 Use according to the intended purpose

The MAFELL door lock mortiser SKS 130 is exclusively intended for mortising doors made of solid wood or common derived timber products, using the mortising chains approved by us.

The door lock mortiser may not be used to mortise metal doors!

The dimensions of the mortising chain set used (guide rail, mortising chain, and chain wheel) must correspond to the mortising chain sets listed in the operating instructions.
Any other use than described above is not permissible.

The manufacturer cannot be held liable for any damage arising from such other use. So as to use the machine as intended, comply with the operating, maintenance, and repair instructions specified by Mafell.

2.9 Residual risks

Danger
Even if used in accordance with its intended purpose and despite confirming the safety instructions, residual risks caused by the intended use will always remain.

• Touching the mortising chain in the exposed area.
• Touching the part of the mortising chain that protrudes below the workpiece when mortising.
• Touching the mortising chain from the side.
• Breakage of the mortising chains and risk of the mortising chains or parts of them being hurled away.
• Touching live parts with the housing open and the mains plug not removed.
• Hearing can be impaired when working for long periods without ear protectors.
• Emission of harmful wood dust during longer operation without extraction.

Safety instructions

Danger
Always observe the following safety instructions and the safety regulations applicable in the respective country of use!

General instructions:

• Children and adolescents must not operate this machine. This rule does not apply to young persons receiving training and being supervised by an expert.
• Never work without the protection devices prescribed for the respective operating sequence and do not make any changes to the machine that could impair safety.
• When operating the machine outdoors, the use of an earth-leakage circuit-breaker is recommended.
• Damaged cables or plugs must be immediately replaced.
• Avoid sharp bends in the cable. Especially when transporting and storing the machine, do not wind the cable around the machine.

Instructions on the use of personal protective equipment:

• Always wear ear protectors during work.
• Always wear a dust mark during work.

Instructions on operation:

• Provide for an unobstructed and slip-proof location with sufficient lighting.
• Do not work on workpieces that are too small or too large for the capability of the machine.
• Clamp mortising chains and guide rails appropriately and keep them in order. Repair defective mortising chains professionally before reuse. Only use sharp mortising chains!
• Only remove the chain guard for tool change purposes, immediately screw it back on again afterward. Never work without a chain guard!
• Never transport the chain mortiser with running mortising chains! Avoid touching the ground with the running mortising chain.
• The switch may not be wedged.
• Before switching on, check whether the mortising chains are properly tensioned.
• Whenever possible secure the workpiece from pivoting or sliding away, overturning and luffing up,e.g by means of clamps.
• Only begin mortising the workpiece when the mortising chains have reached their full speed.
• Examine the workpiece for foreign objects. Never attempt to mortise into metal objects, such as nails.
• Hold on tightly to the machine, already before turning it on. The mortising chains must stand unrestricted. Apply the machine for the mortising operation with running mortising chains. Pay attention to a secure footing.
• Never reach below or laterally onto the workpiece during mortising (Risk of injury!).
• Always lead the connecting cable away from the machine to the rear while mortising.
• Match the feed speed during mortising to the material thickness. Mortising too quickly leads to motor overload, to unclean mortises and to the mortising chains blunting quickly.
• Only remove the machine from the workpiece if the mortising chains have come to a standstill.
• Do not reach into the chip ejector and the unprotected area of the mortising chain while the machine is running.
• The wood dust arising during mortising impairs the necessary view and is partly injurious to health. If the machine is used for longer periods, it must therefore be connected to a chip extractor, e.g. a portable small extractor, if the work is not carried out outdoors or in a sufficiently ventilated room. The air velocity must be at least 20 m/s (65.6 ft/sec.).

Instructions on service and maintenance:

• Regularly cleaning the machine, especially the adjusting devices and guides, constitutes an important safety factor.
• Only original MAFELL spare parts and accessories may be used. Otherwise, the manufacturer will not accept any warranty claims and cannot be held liable.

Setting/Adjustment

4.1 Mains connection

Prior to commissioning make sure that the mains voltage complies with the operating voltage stated on the machine’s rating plate.

4.2 Chip extraction
Connect the machine to a suitable external dust extractor during all work generating a considerable amount of dust. The air velocity must be at least 20 m/s (65.6 ft / sec.).
The inside diameter of hose connector 7 (Fig. 2) is 35 mm (1 3/8 in.).

4.3 Mortising chain change and chain wheel change

Danger
Pull the power plug during all service work.

Pay attention that the mortising chains to be clamped have been well sharpened as this is a basic requirement for correct mortising.
Proceed as follows for exchanging the mortising chain:

• Clamp the machine vertically onto a piece of wood so that the machine cannot overturn.
• Unfasten screw 9 (Fig. 2) and remove the chain guard 8.
• Slacken the mortising chains 4 (Fig. 1) by unfastening the two screws 3.
• Unfasten the screws 6.
• Push the guide rails 1 in direction of the chain wheels 2.
• Remove the chain wheels, mortising chains, and guide rails.
• Place the new mortising chains onto the guide rails. Pay attention to the direction of travel (see the direction of travel arrows on the chain guard).
• If necessary, place new chain wheels into the mortising chains.
• Refit the chain wheels, mortising chains, and guide rails. In doing so, push the chain wheels onto the gear shaft in such a manner that the chain wheel groove gears into the straight pin, and the circlip engages in the gear shaft groove.
• Slightly unfasten the screws 5.
• Slightly tighten the screws 6 and tension the mortising chain with the screws 3. The correct chain tension has been achieved if the mortising chain can be lifted by approx. 6 mm (1/4 in.) in the center of the guide rails.
• Tighten the screws 5 and 6.
• Refit the chain guard 8 (Fig. 2) and secure it with screw 9.

Operation

5.1 Initial operation
Personnel entrusted to work with the machine must be made aware of the operating instructions, calling particular attention to the chapter “Safety instructions”.

5.2 Switching on and off

Danger
Pay attention that the mortising chain can be moved freely.
Lead the connecting cable away to the rear.
Hold onto the machine with both hands.
Only switch on the machine if the mortising chain has no contact with the workpiece.

• Switching on: First unlock the switch-on lock by pressing the lock-off button 10 (Fig. 2). Then, keeping the lock-off button depressed, activate the switch trigger 11. The mortising chains are running and the feed is unlocked.
• Switching off: To switch off, release the switch trigger. Pull the machine completely back into the latching position.

5.3 Positioning on doors with rebate

For positioning and aligning the door lock mortiser on doors with a rebate, heed the red symbols on the left-hand side!

Danger
Secure door against sliding away, overturning, and luffing up!

• Apply the machine to the door as shown in Fig. 3. They stop edges (red arrow) are now about the rebate from the inside.
• Align the machine in the longitudinal direction. To do so, align the red edge 24 (Fig. 5) with the protective cover 16 (Abb. 2) on the left or right marking for the lock casing.
• Clamp the sliding bevel segment 21 (Fig. 3) against the door leaf by turning the handle 20. Select clamping force in accordance with door stability! If necessary, an interim layer, e.g. a wooden board, can be screwed onto the sliding bevel segment.
• Unfasten the wing screw 18.
• Set the spacing between the center lock casing and rebate by shifting the base plate 19. The spacing can be read off with a scale 22 on the red indicator edge.
• Retighten the wing nut 18.

5.4 Positioning on doors without rebate

For positioning and aligning the door lock mortiser on doors without a rebate, heed the black symbols on the right-hand side!

Danger
Secure door against sliding away, overturning, and luffing up!

• Apply the machine to the door as shown in Fig. 4. The stop edge (black arrow) that is provided with a sliding coating abuts the door leaf.
• Align the machine in the longitudinal direction. To do so, align the red edge 24 (Fig. 5) with the protective cover 16 (Abb. 2) on the left or right marking for the lock casing.
• Clamp the sliding bevel segment 21 (Fig. 3) against the door leaf by turning the handle 20. Select clamping force in accordance with door stability! If necessary, an interim layer, e.g. a wooden board, can be screwed onto the sliding bevel segment.
• Unfasten the wing screw 18.
• Set the spacing between the center lock casing and stop edge by shifting the base plate 19. The distance can be read off with scale 23 (Fig. 4) on the black indicator edge.
• Retighten the wing screw 18 (Fig. 3).

5.5 Positioning on built-in doors

Danger
Secure door against pivoting! Even after it is clamped tight, the operator must keep hold of the door lock mortiser with both hands!
Never leave the door lock mortiser clamped onto the door!
Remove the door lock mortiser from the door immediately after mortising.
If possible, dismount the door and mortise the door in a horizontal position.

• Apply the machine to the door as shown in Fig. 5.
• Position and align the machine (see chapter 5.3 or 5.4). To facilitate the alignment in the longitudinal direction in this position, the protective cover 16 (Fig. 2) is equipped with two recesses 25 (Fig. 5). This improves the visibility of the red edges 24.

5.6 Mortising depth adjustment

The mortising depth is continuously variable between 0 and 145 mm (0 to 5 3/4 in.).

Proceed as follows to adjust it:

• Pull the machine by its handle 12 (Fig. 2) back into the home position so that the machine is engaged.
• Unfasten the wing screw 13.
• Adjust the mortising depth by shifting the adjusting ring 14. The mortising depth can be read off with a scale of 15 on the depth indicator 17.
• Retighten the wing nut.

5.7 Mortising the lock casing

Danger
Avoid mortising residues as shown in Fig. 6! This spares the machine and the workpiece.
Hold the machine by both handles 12 (Fig. 2) and 20 (Fig. 3) during mortising.

• Position the machine on the door (see chapters 5.3, 5.4, or 5.5).
• Set the mortising depth (see chapter 5.6).
• Hold onto the machine with both hands. Switch it on (see chapter 5.2) and mortise with even feed up to the limit stop.
• Pull the machine back into its home position.
• Release the switch trigger 11 (Fig. 2). The machine is locked.

During a mortising operation, a lock pocket length of 78 mm is achieved. For longer lock pockets, the machine must be reapplied.

• To do so, slightly unfasten the handle 20 (Fig. 3). Slightly tilt the machine and shift it.

Service and maintenance

Danger
Pull the power plug during all service work.

MAFELL machines are designed to be low in maintenance.
The ball bearings used are greased for life. When the machine has been in operation for a longer period of time, we recommend handing the machine in at an authorized MAFELL customer service shop for inspection.
Only use our special grease, order No . 049040 (1 kg) for all greasing points.

6.1 Mortising chains
The mortising chain used on the machine should be cleaned and lubricated in a low viscosity oil bath after two hours of operation. To do so, dismantle the mortising chain (see chapter 4.3).
Replace the blunt mortising chains or have them reground at a MAFELL customer service station or by a suitable sharpening service.

6.2 Storage
If the machine is not used for a longer period of time, it has to be carefully cleaned. Spray bright metal parts with a rust inhibitor.

Troubleshooting

Danger
Determining the causes for existing defects and eliminating these always requires increased attention and caution. Pull the mains plug beforehand!

Some of the most frequent defects and their causes are listed in the following chart. In case of other defects, contact your dealer or the MAFELL customer service.

Defect

| Cause|

Elimination

---|---|---
The machine cannot be switched on| No mains voltage| Check power supply
Mains fuse defective| Replace fuse
Carbon brushes worn| Take the machine to a MAFELL customer service shop
The machine stops while mortising are in the process| Mains failure| Check mains backup fuses
Machine overloaded| Reduce feed speed
Unfavorable residue mortising (see Fig. 6)| Relocate the machine and mortise the residue with a chain
Chip ejection blocked| The wood is too damp|
Extended mortising without exhaustion| Connect to an external extraction, e.g. portable dust extractor

Exploded drawing and spare parts list

The corresponding information in respect of spare parts can be found on our homepage: www.mafell.com

WARRANTY

Upon presentation of the warranty document (original invoice), we will carry out all repairs free of charge in accordance with the applicable warranty provisions, processing, and mounting faults free of charge on presentation of this properly filled-in Guarantee Certificate and your original receipt. This is not valid for consumables and wearing parts. For this purpose, the machine or the appliance is to be forwarded freight paid to our plant or to an authorized MAFELL repair service. Refrain from trying to carry out the repairs yourself as otherwise, your warranty claim will become extinct. We do not accept any liability for any damage resulting from improper handling or normal wear.

MAFELL AG
Postfach 1180, D-78720 Oberndorf / Neckar,
Telefone: +49 (0)7423/812-0
Fax: +49 (0)7423/812-218
Internet: www.mafell.de
E-Mail: mafell@mafell.de

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